Multistage Polymer Composition for Thermoset Impact Modification

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Solution Overview

Problem

Existing thermoset polymers are brittle and have low fracture toughness, making them inadequate for applications requiring impact resistance and mechanical stability over a wide temperature range.

Innovation Solution

A composition comprising a multistage polymer and a thermoplastic polymer, with a compound having two polymerizable groups, is developed. This composition is designed to be easily dispersed in polymeric matrix materials for thermosetting polymers, ensuring homogeneous distribution and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thermoset polymers are used to achieve excellent dimensional stability, mechanical strength, and heat resistance, then the material becomes brittle and has low fracture toughness

Engineering Contradiction:

Improvemechanical strengthVSAvoidbrittleness

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention uses a composite system combining thermoset polymer matrix with dispersed multistage polymer particles. The thermoset matrix provides mechanical strength and dimensional stability, while the multistage polymer particles act as impact modifiers to reduce brittleness. This composite approach allows simultaneous achievement of both strength and toughness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The multistage polymer particles are designed with specific glass transition temperatures to provide localized flexibility within the rigid thermoset matrix. The particles create zones of different mechanical properties throughout the material, allowing the bulk material to maintain strength while localized regions absorb impact energy.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If multistage polymers are added to improve impact resistance, then the dispersion becomes difficult to achieve homogeneously and quickly

Engineering Contradiction:

Improveimpact resistanceVSAvoiddispersion time

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The invention specifies precise parameter ranges for the multistage polymer including glass transition temperature (Tg between -50°C to 50°C), particle size (0.1 to 10 μm), and composition ratios. These controlled parameters ensure optimal dispersion characteristics and reduce the time required to achieve homogeneous distribution in the thermoset matrix.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The multistage polymer particles are pre-synthesized with controlled morphology and size distribution before being incorporated into the thermoset matrix. This preliminary preparation of the particles with optimal characteristics facilitates faster and more uniform dispersion during the composite fabrication process.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If the glass transition temperature of the thermoplastic polymer is increased to at least 30°C, then the impact resistance improves, but the preparation time increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidpreparation time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The invention uses a moderate amount of thermoplastic polymer (1-50 phr per 100 phr thermoset polymer) with specific Tg range to achieve sufficient impact resistance without excessive preparation time. This partial action approach provides the necessary toughness improvement while maintaining efficient processing speeds.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The proposed composition effectively enhances the impact resistance and mechanical properties of thermoset polymers, achieving stable and homogeneous dispersion while reducing preparation time.

Implementation Method 1

c) a component (LC1) comprising a compound (C1) with at least two polymerizable groups (PG1) and (PG2)

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS12312469B2Composition comprising a compound with two polymerizable groups, a multistage polymer and a thermoplastic polymer, its method of preparation, its use and article comprising it

Publication Date: 2025.05.27 ARKEMA FRANCE SA

AI summary

The present invention relates to a composition comprising a compound with two polymerizable groups, a multistage polymer and a thermoplastic polymer its process of preparation and its use. In particular the present invention relates to a composition comprising a compound with two polymerizable groups, a multistage polymer in form of polymeric particles made by a multistage process and a (meth)acrylic polymer. More particularly the present invention relates to polymer composition comprising a compound with two polymerizable groups, polymeric particles made by a multistage process comprising at least two stages and a (meth)acrylic polymer, its method of preparation, its use for making impact modified polymer compositions, comprising thermosetting resins and compositions and articles comprising it.